Textile materials with fireproof additive and method for producing

Abstract

A flame-resistant additive for textile materials and microfiber non-woven fabrics of the artificial-leather type that imparts a high level of fireproofing properties to the textile material treated without negatively affecting the visual and mechanical characteristics, softness to the touch. The flame-resistant additive includes a fireproofing component having a finely divided mixture of melamine and melamine cyanurate and a clay or other adsorbent material such as diatomaceous earth, zeolite, inorganic oxides such as alumina, silica, magnesium oxide or mixtures of inorganic oxides and a binder which includes an aqueous dispersion of an acrylic or maleic polymer or copolymer and a multifunctional cross-linker of the acrylic or maleic polymer or copolymer.

Description

1. Field of the InventionThis invention relates to a flame-resistant agent for the treatment of non-woven fabrics, a procedure for its preparation and the non-woven fabrics made fireproof as a result of treatment with the flame-resistant agent.2. Description of Prior ArtMicrofiber non-woven fabrics are known in the art, for instance, the type produced by ALCANTARA S.p.A. Products of this type are also described in Italian patents 823,055; 839,921; 858,373; 873,699; 905,222; 921,871 and in U.S. Pat. Nos. 3,531,368 and 3,899,623.For numerous final applications, for instance furnishing, and in some markets for almost all uses, the microfiber fabrics must conform to precise flame resistance requirements.There are essentially three procedures known for endowing microfiber fabrics with the required flame-resistant characteristics. According to a first procedure, known as padding, the fabric is subjected to impregnation in a bath containing flame-resistant additives and subsequently dried....

AI Technical Summary

Benefits of technology

The quantity of flame-resistant additive in accordance with this invention necessary to render the non-woven fabric material fireproof is appreciably less than the quantity of conventional flame-resistant additives necessary to provide the same degree of fireproofing. This quantity is preferably in the range of about 15% to about 60% by weight of the material to be treated, and is more preferably in the range of about 20% to about 40%. It is believed that the high degree of subdivision of the flame-resistant additive according to the invention, in addition to the dispersing and deflocculant action of the adsorbent support, favors the penetration of the fabric by the same, so improving the fireproof characteristics.

In accordance with one preferred embodiment of this invention, the flame-resistant composition is prepared directly at the moment of use or immediately prior to use so as to limit storage problems.

A significant characteristic of the additive in accordance with this invention is that it can be used in large quantities, thereby imparting a high level of flame-resistance to the materials treated, without reducing the aesthetics and softness to the touch of the product.

The fine subdivision of the additive improves the adherence of the same to the material to be treated and that makes possible products that don't show "powdering" phenomena i.e., the separation of the additive.

Problems solved by technology

This process has the disadvantage of giving a "buffed suede" finish that has worse hand and softness characteristics than the original non-flame-resistant product.

Furthermore, this treatment is not permanent.

This method does not have the disadvantage of padding in as much as the "front" side of the fabric is not affected by the treatment, but given the large quantity of flame-retarding compounds required to confer the desired effect, the treated product presents a "harder" hand and is therefore less drapable than the non-treated product.

Although guaranteeing flame resistance, the combined use of intrinsically fireproof microfiber polymers and additives (in varying proportion to the polyurethane) reflects negatively on the visual appearance (short nap, specking), the drapery (hard hand), and the dyeing characteristics (tone), even though the physical-mechanical performance remains within the required range.

However, there is a tendency towards ever stricter regulations that could lead in the future to the imposition of severe limitations on the use of halogen compounds as components of fireproofing agents.

The use of antimony derivatives could also be legally restricted in the future, with negative consequences for its wide use as a component of flame-resistant agents.

However, despite some phosphorus derivatives being known which show fireproof activity, compounds that simultaneously answer all the requirements established above, when applied to products of the artificial-leather type based substantially on microfiber non-woven fabrics are still not known.

Trials carried out on a large number of compounds containing phosphorus derivatives to determine their suitability as fireproofing agents for materials of the artificial-leather type constituted substantially of microfiber non-woven fabrics have shown that such additive products, while having good fireproofing characteristics, have evident aesthetic deficiencies.

Another problem posed by the use of phosphorus derivatives as flame-resistant agents is that of identifying a binder that, on one hand, allows homogeneous distribution of the additive and yet prevents its separation from the treated product.

As far as properties related to the visual appearance of the product are concerned, it has been found that the application of these flame-resistant compounds imparted a damp or even wet appearance to the product.

Such additive, while conferring excellent fireproofing characteristics on the products treated that remain even after repeated dry cleaning, showed the formation of stains on the fabric when the fabric was brought into contact with water.

Therefore the problem of making textile materials, in particular microfiber non-woven fabrics, fireproof in an effective and stable way without influencing the characteristics of the product substantially or negatively, has still not been completely resolved.